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2 INTRODCTION TABLE OF CONTENTS Contents Page Introduction 2 Features and Benefits 3 Description Radial Piston Pump 4 Description Digital Control Version 5 Functionality 6 Basic Hydraulic Circuits 8 Configuration Software 10 Communication Standard 11 Parameter Sets 12 Electrical Interfaces 13 Accessories 18 Model Code 19 Conversion Table 22 Global Support 23 IMPORTANT NOTE The information contained herein is intended for users with some technical knowledge of RKP pumps. To ensure that all necessary characteristics for function and safety are covered, the user must check the suitability of the products described herein. Additional technical information and operating instruction can be found in the main RKP catalogs available from Moog. These products are subject to change without notice. Moog is a registered trademark of Moog Inc. and its subsidiaries. nless expressly indicated, all trademarks indicated herein are the property of Moog Inc. and its subsidiaries. For a complete disclaimer, please go to literature/disclaimers. Moog Inc All rights reserved. All changes are reserved. For the most current information, visit EXCELLENCE IN MOTION CONTROL For over 50 years, Moog has been a leader in motion control technology, specializing in manufacturing and applying high performance products. Today, Moog continues to incorporate the latest motion control technology to offer innovative products that can help customers, to achieve new levels of machine performance. PROVEN PMP TECHNOLOGY Moog s Radial Piston Pump product line (also known as RKP) is a high performance variable displacement pump for industrial applications. Based on a proven concept, RKP s robust and contamination-resistant design allows for long life and high reliability. Its ability to deliver rapid response time and high volumetric efficiencies, has made it the choice for many machines with demanding flow, pressure and power control needs. Moog produces a wide range of Radial Piston Pumps in different sizes, single and multiple arrangements, and with various controls (mechanical, hydromechanical, electrohydraulic, digital and analog) in order to provide maximum flexibility to machine builders. DIGITAL OR ANALOG CONTROL With this new version, Moog has significantly improved the control technology of the RKP with a new closed-loop proportional valve with digital on-board electronics for flow and pressure regulation, tuning, and diagnostics. Moog s new RKP-D can be digitally controlled via a CANopen interface or run as a purely analog device controlled by analog command signals. This provides maximum flexibility for compatibility with several PLC architectures. Described in this document are details about the significant benefits available from running the RKP-D in either analog or CANopen modes. CONFIGRATION SOFTWARE One key advantage of the new RKP-D is the ability of the user to perform fast and convenient commissioning, diagnostics, and configuration with the Moog Configuration Software. This Microsoft Windows -based software communicates with the RKP-D via the CANopen fieldbus. It can be installed either in the machine s PLC (using the Human Machine Interface (HMI)) or on a laptop computer. Set values, actual values, status information, and all relevant parameters are displayed graphically and may be modified easily or run with factory presets. Additional tools, such as the integrated oscilloscope and the function generator, help to facilitate the commissioning of the device. This software is free and can be requested by Moog. APPLICATIONS The high-performance, flexible control system used for this new RKP-D makes it the ideal solution for pressure, flow and power controlled hydraulic systems of any kind. It is especially valuable for sequential machine processes, which require adaptation of the RKP-D parameters during operation. RADIAL PISTON PMP RKP-D 2

3 FEATRES AND BENEFITS GENERAL In addition to reliability and performance, the Radial Piston Pump is known for its modular functionality, which enables tailored pumps or combinations ideally suited to an application. Features: Seven sizes between 19 and 140 cm 3 /rev (1.2 and 8.5 in 3 /rev) Large selection of controls Multiple pumps configurations by axial mounting Suitable for various hydraulic fluids Standard pressure series 280 bar (4,000 psi) and high pressure series 350 bar (5,000 psi) for mineral oil Rapid response time Compact design Good suction characteristics Low pressure ripple Low noise level Precise Closed-Loop Control The new pilot valve with digital onboard-electronics provides more dynamics and improved precision control of flow and pressure regulation, while offering a range of advanced functions. Machine processes driven by this new RKP-D have higher repeatability and better quality of the finished parts. Analog or CAN-bus Operation The ability to function as a CANopen device or as a traditional analog device ensures compatibility with different PLC-structures. When operating as an analog device, the RKP-D uses purely analog command signals to control flow and pressure and can select the matching parameter set. Consequently, this RKP-D provides many benefits of digital control without requiring a CAN-bus interface into the machine s PLC. Optimized Multiple Pump System With the introduction of the new master-slave mode, it is now possible to combine multiple servopump-stages in one common oil volume, while provides superior pressure control. This is an innovation, provide for the most flexible use of double- or triple pumps in complex machine processes. This option allows either separate pump stages for parallel movements or to combine flows, in order to achieve highest velocities in isolated motions. Both cases take advantage of the superior pressure regulation possibilities of RKP-D. This feature enables users to arrange axis motions with a high degree of flexibility, without being forced to compromise the quality of the pressure control. Advanced Troubleshooting Real-time diagnostics with full access to internal parameters via the Human Machine Interface (HMI) or a laptop PC improves uptime and reduces maintenance costs. In addition, the fail-safe-behavior of the RKP-D can be adapted to the requirements of the machine process. Saving Space and Assembly Time The basic RKP-D functions (p and Q) are preadjusted to save time during assembly and commissioning. Since all necessary electronic functions are integrated in the pilot valve, an external po-card is not required and therefore no need to provide cabling to/from the RKP-D. Warranty The Moog Radial Piston Pump stands for reliability, low noise and durability. This is underlined by its extended warranty. nder the conditions described in section "Technical Data" of the main catalogues RKP and RKP-II, warranty for mineral oil is covered for 10,000 operating hours or 24 months. On the Fly Adjustment In a sequential machine process, one single RKP-D typically drives different cylinders one after the other, with each requiring specific RKP-D settings. Now it is possible, to change the parameters of the RKP-D on the fly, including setting of the pressure controller, activation of different operational modes and selection of different pressure sensors. This enables adaptation of the RKP-D behavior to the specific requirements of each cycle step. The end result is greater consistency and shorter cycle time of the whole machine process. RADIAL PISTON PMP RKP-D 3

4 DESCRIPTION RADIAL PISTON PMP MODE OF OPERATION The shaft (1) transfers the drive torque to the star-shaped cylinder block (3) free of any transverse forces via a crossdisc coupling (2). The cylinder block is supported on the control journal (4). The radial pistons (5) in the cylinder block abut against the stroke ring (7) through hydrostatically balanced slipper pads (6). Piston and slipper pad are joined by a ball and socket joint, which is locked by a ring. The slipper pads are guided in the stroke ring by two overlapping rings (8) and, when running, are forced against the stroke ring by centrifugal force and oil pressure. As the cylinder block rotates, the pistons perform a reciprocating motion due to the eccentric position of the stroke ring, the piston stroke being twice the eccentricity. The eccentric position of the stroke ring can be altered by means of two diametrically opposed control pistons (9, 10) in the pump body. The oil flow to and from the pump passes through ducts in the body and control journal, and is controlled by the suction and delivery ports in the latter. The rolling bearing, supporting the drive, shaft is subjected to external forces only. At the RKP-D the position of the stroke ring is detected by an LVDT (11) and high dynamically controlled by a servo pilot valve (12) GENERAL DESCRIPTION OF RKP-D The Radial Piston Pump with digital control (RKP-D) is an electrohydraulically controlled Radial Piston Pump that has a closed-loop servo pilot valve with digital on-board electronics for control of flow and pressure. The valve electronics contain a microprocessor system, that executes all essential functions. All control circuits are processed by the software including: Position control of the pilot valve Position control of the stroke ring (flow control) Pressure control The high performance and flexible control concept of this RKP-D offers broad functionality, making this an ideal solution for hydraulic systems with demanding requirements for flow and pressure control. RADIAL PISTON PMP RKP-D 4

5 DESCRIPTION DIGITAL CONTROL VERSION FLEXIBLE CONTROL OPTIONS Signals can be exchanged between the RKP-D and the machine controller either by means of the CAN-bus interface (CAN-bus mode) or as analog signals (analog mode). This type of pump can be easily integrated into machine control systems with either CANopen interface or analog output signals. The RKP-D with digital control offers easy integration into different control approaches to make it flexible for the widest range of machine requirements. Some available options include: Factory-Preset Analog Condition: The RKP-D comes from the factory set-up in an analog mode. This allows it to be operated as a plug and play device commanded by analog setpoint signals for flow and pressure as well as factory pre-sets for all key parameters. This enables easy and quick set-up for those users with basic requirements. Parameter Set Selection Analog Condition: sers that need a higher degree of adaptation to unique machine requirements, need only provide the RKP-D with an additional V signal, to enable easy selection of parameter sets. STRCTRAL DESIGN This feature greatly increases the options for adapting the RKP-D behavior to machine processes, including the transition from one parameter set to another on the fly. While this option provides opportunities for much higher performance of the RKP-D, it is still an analog mode for easy operation and requires no knowledge of CAN-bus systems or software. Software Configurable Analog Condition: sers that want the full set of options in analog mode for modifying the RKP-D settings can also use the Moog Configuration Software to modify the factory settings including the pre-defined parameter sets. Whether in commissioning or during operation, adjustments can be made based on the requirements of the specific machine process. The software is specially designed by Moog and is based on our extensive experience with hydraulic products. It is available on request as part of the package. CAN-bus Operating Condition: Pumps can also be fully controlled via a CAN-bus interface and Moog Configuration Software, thereby offering the full range of flexibility and functionality. This CAN-bus mode is ideally suited to the most demanding requirements and allows knowledgeable users to program easily and discover new ways to optimize performance. X3/X4 X7 X1 analog parameter selection analog feedback analog commands power supply CAN open A D default analog mode CAN interface parameters P object library flow command pressure command p parameters enable default sensor X6 X5 X6 P slave solo master Q min II T P default solo mode s B A X2 option (only controller X8 types D5/D6) s RADIAL PISTON PMP RKP-D 5

6 FNCTIONALITY FNCTIONS OF THE RADIAL PISTON PMP WITH DIGITAL CONTROL Flow Control The RKP-D controls the position of the stroke ring in accordance with the specified flow set point in a closed-loop regulation. Depending on the selected RKP size (19, 32, 45, 63, 80, 100, 140 cm 3 /rev), a pump flow of % is made available. The flow-rate setting is factory-calibrated, such that the RKP-D produces a flow rate of 0% at a Q set point value of 0 V and a flow rate of 100% at a Q set point value of 10 V. The parameters for the digital Q controller are factory-set and cannot be altered by the user. Pressure Control The pressure control function works by continuously comparing the system pressure (determined via the pressure sensor) with the current pressure set point. If the system pressure exceeds the pressure set point, the RKP-D will reduce its flow until the desired pressure is no longer exceeded. The RKP-D can switch into active suction mode (negative flow) during pressure control, which allows fast pressure reduction in a connected oil volume. The user can harmonize the parameters of the digital pressure controller with the existing hydraulic system. Sixteen complete parameter sets have been predefined to facilitate this procedure. They may be selected and also switched during operation via an analog 0 to 10 V signal or the CANbus interface. The user can choose from two pressure-sensor connections in order to achieve the target pressure. It is possible to switch between these two sensors during operation. The pressure-sensor inputs are configurable, thereby permitting the connection of several types of pressure sensors ( ma; V; 2-, 3- and 4-wire sensors). Pressure Control The power control function works by continuously computing the hydraulic power, which is a product of the current pressure (load) and the current stroke ring position (flow). Should the current power reach the pre-defined limit, the flow can not be longer increased. Leakage Compensation As the pressure increases, pumps will produce increasing internal leakage that will be missing from the usable volume flow that is normally generated by the pump. The pump electronics contain a leak-compensation function to cancel out this effect. As the system pressure increases, the flow volume increases automatically so that the useful volume flow remains virtually constant. This function is preset at the factory, but can be adjusted to actual machine conditions (to compensate for system leakages) or switched off entirely depending on a customer s unique needs. Internal Flushing Function This special function is included in RKP-D models with an internal pressure supply (controller D1, D4, D5 and D8). The RKP-D monitors changes in the set points of pressure (p) and volumetric flow rate (Q). If one of the setpoints is < 1% for 3 minutes, the pilot valve is switched off, goes to its fail-safe-position, and flushes the RKP-D housing. This limits the temperature of the RKP-D. Housing temperatures up to 90 C (195 F) are acceptable and do not damage the RKP-D. To deactivate the flushing function, both set points have to be >1%. Master-Slave Operation Master-Slave operation may be used in set-ups where several pumps are combined into one system. In this case, there must be only one active pressure controller (master), while the remaining pumps (slaves) are purely flow controlled by the master pump. During this Master-Slave operation, the master will communicate his flow value via the local CANbus to the slaves. The advantages of the Master-Slave operation is the stable pressure control at a synchronous flow. This operating mode can be switched on and off using the CAN-bus interface, as well as by using analog selection of the corresponding parameter set. Please note that only pumps with controller options D5 to D8 are equipped with a local CAN-bus and thus are able to perform this Master-Slave operation. Further, the definition of which pump is the master and which is the slave in a multiple pump arrangement must be completed during initial commissioning of the RKP-D, using the Moog Configuration Software or CAN-bus. RADIAL PISTON PMP RKP-D 6

7 FNCTIONALITY Hybrid Mode In the hybrid mode, a RKP-D is merged with a constant pump in a shared volume. In the standby-condition, the RKP-D must pump to the tank (in a negative flow direction) some or all of the constant pump's flow volume. This condition allows us both to adjust the flow rate and to control the pressure. Generally, a flow ratio of 100:80 (100:60 is ideal) between the RKP-D and constant pump may not be exceeded. The RKP-D s electronics afford the option of activating a second flow calibration by switching to the hybrid mode, which makes the generation of negative set point values by the customer's control system unnecessary. Please note that this second flow adjustment (gain and offset) is not factory preset and must be calibrated by the user during initial commissioning. For easy use, there is a predesigned menu for flow adjustment in the Moog Configuration Software. RKP-D s for hybrid operation have special design features and thus are identified by dedicated model codes (controller option D3, D4, D7 and D8). Special Feature for Injection Molding - Local Holding Pressure Switchover This special function provides a solution to a common problem encountered during the transition from the speed to the hold pressure phase, when controlling the injection process of injection molding machines. When operating the RKP-D in CAN-bus mode, small but unavoidable delay times appear while transferring the set points between the machine s PLC and the RKP-D. These delay times, which may vary within certain limits, limit the repetitive accuracy of the hold pressure switchover of injection molding machines. To overcome this problem, the RKP-D provides a special software function, called Local Hold Pressure Switchover, which independently accomplishes the transition from the speed to the hold pressure phase in almost real time using the control electronics. This happens without intervention by the superior PLC and therefore without disturbing signal running times over the CAN-bus. This function can be used only during CAN-bus operation of the RKP-D and is generally only needed in this operating mode. The Principles of Hybrid Consumer 1 Sequence valve Consumer 2 Functional Principle of the Local Holding Pressure Switchover Injection Trigger threshold 1. Holding pressure v p 2. Holding pressure Q = 100 % Q = 80 % Holding pressure switchover Pump operates independently t 10 V Internal Q-command Solo-mode Hybrid mode 0 V 10 V External Q-command max. -8 V Displacement of the fixed pump RADIAL PISTON PMP RKP-D 7

8 BASIC HYDRALIC CIRCITS RKP-D WITH INTERNAL PRESSRE SPPLY WITHOT SEQENCE MANIFOLD The pilot valve (D930) controls the position of the stroke ring by influencing the pilot oil flow inside the large control piston. The p-port of the pilot valve, as well as the small control piston on the opposite side, are connected to the RKP-D pressure line. The pilot valve of the RKP-D versions with internal pressure supply is equipped with a special fail-safe position, allowing internal flushing of the RKP-D housing in standby-condition (command signals = 0). In order to work properly, the pilot system of the RKP-D in models with internal pressure supply (controller options D1, D4, D5 and D8) needs to be supplied with a pilot pressure 14 bar (200 psi). Hence, in the configuration shown below, the output pressure of the RKP-D (load pressure of the attached cylinder or hydromotor) must never fall below 14 bar (200 psi), otherwise the pilot system looses control of the stroke ring position and the RKP-D goes for 100% flow. Digital OBE S Pilot Valve D930 T P B A L B Pump Drive This behavior protects the RKP-D in case of fail-safesituations and is caused by the spring configuration of the stroke ring, which corresponds to a system pressure of approximately 11 bar (160 psi). E S Position Transducer A L RKP-D WITH INTERNAL PRESSRE SPPLY WITH SEQENCE MANIFOLD In cases where the system pressure cannot be maintained continuously above 14 bar (200 psi) (e.g. with low friction cylinders moving at zero load), it is necessary to apply a pressure-sequence manifold, which is available as accessory. The built-in pressure sequence cartridge maintains the minimum required pilot pressure of 14 bar (200 psi), in case the system pressure falls below this value. The sequence cartridge does not have an impact on energy consumption due to its special design, which avoids any functional pressure drop above a static pressure level of 20 bar (290 psi). Additionally, the sequence cartridge allows a decrease of the system pressure down to 0 bar (0 psi), which would normally not occur, due to the natural spring pressure of about 11 bar (160 psi). The sequence manifold is mounted directly on the outlet of the RKP-D and contains additional functions as follows: p max -limitation (safety function) General-purpose measuring ports e.g., assembling a pressure transducer A check-valve to bypass the sequence cartridge during decompression of system pressure below 14 bar (200psi). Sequence Manifold Digital OBE Pilot Valve T M1 L 14 bar PS B Pump Drive X1 PP P M2 M3 Pressure Sensor S T B P A S E A L RADIAL PISTON PMP RKP-D 8

9 BASIC HYDRALIC CIRCITS RKP-D WITH EXTERNAL PRESSRE SPPLY The illustration below shows the application of a model with external pressure supply. This RKP-D version contains a shutter-valve in the p-line of the pilot valve and is equipped with different springs in the control pistons, which results in a low natural pressure of about 1 bar (15 psi). To achieve sufficient RKP-D performance at low system pressures, it is required to apply an additional constant displacement pump, which ensures a minimum control pressure level. A cost-saving solution to this problem is to use the cooling and filtration circuit for this purpose, as shown below. Due to the function of the shutter-valve, the pilot system is supplied directly from the RKP-D outlet at higher systempressures. The recommendations for the selection of the supplementary pump (in general a gear pump) are as follows: Pressure: bar ( psi) minimum displacement: RKP-D cm 3 /rev => V = 6 l/min (1.6 gpm) RKP-D cm 3 /rev => V = 12 l/min (3.1 gpm) RKP-D 140 cm 3 /rev => V = 16 l/min (4.2 gpm) Please note that models with external pressure supply (controller option D2, D3, D6 and D7) do not include an automatic flushing function. Therefore the user of the RKP-D is responsible for the thermal balance of the RKP-D, especially in standby-condition. Depending on the specific circumstances, it may be necessary to flush the RKP-D externally (see also Set-up and Operating Instructions). Pilot valve F L B Digital OBE Pump Drive S T B P A >25 bar Gear Pump S E A L Position Transducer RADIAL PISTON PMP RKP-D 9

10 CONFIGRATION SOFTWARE GENERAL The Windows -based Moog Configuration Software enables fast and convenient commissioning, diagnostics, and configuration of the RKP-D. The software communicates with the RKP-D via the CANopen fieldbus. This requires a PC-installed CAN interface card to allow data to be exchanged between the PC and the RKP-D and for RKP-D settings to be recorded on the PC. The RKP-D configuration is controlled via graphic control elements. Status information, set values, and actual values, as well as characteristic curves, are displayed graphically. The operational behavior of the RKP-D can be visualized and recorded via an integrated oscilloscope/data logger. MOOG CONFIGRATION SOFTWARE The configuration software can be configured on a PC with the following minimal requirements: Screenshot Moog Configuration Software IBM compatible PC with 133 MHz Windows 95/98/ME, Windows 2000/XP 64 MB RAM 20 MB free hard disk memory Monitor 800 x 600 pixel resolution Keyboard, mouse, CD-ROM Recommended requirements: IBM compatible PC with 300 MHz Windows 2000/XP To connect the software with the RKP-D, the following additional equipment is required: A free PCI/PCMCIA slot or SB port CAN interface card (PCI/PCMCIA/SB) Note: Interface card IXXAT SB-to-CANcompact recommended (Moog order code: C ) CAN cable Note: CAN cable Sub-D to M12; with termination resistor recommended. Moog order code: TD Power supply 24V DC/2A (supply for RKP-D electronics) Screenshot Moog Configuration Software connected with the RKP-D via IXXAT interface card and CAN cable RADIAL PISTON PMP RKP-D 10

11 COMMNICATION STANDARD ANALOG OPERATION In the factory preset analog mode of operation, the RKP-D receives its set points for pressure (p) and flow (Q) as analog signals. Additionally, the user can take full advantage of the ability to alter parameter sets in mid-operation, including the following key abilities: To change the setting of the pressure controller To select from two possible pressure-sensor inputs To activate or deactivate the master-slave-operation To activate or deactivate the hybrid mode To activate or deactivate the pressure controller In order to take advantage of all these possibilities, the machine s PLC must provide the following 3 analog output signals: CAN-BS DIGITAL OPERATION In this software configurable CAN-bus mode, the RKP-D is parameterized, activated and monitored via the built-in CANopen-interface in accordance with international standards (CIA-standard DS408 device profile fluid power technology ISO 11898). The CAN-communication of the RKP-D (including the individual pump stages of multiple pumps) is factory-set as follows: Node-ID = 127; Bitrate = 500 kbit/sec. Please note that details are available in Moog CAN-bus Operating Manual. Flow command signal V (factory set) or ma (software configurable) Pressure command signal V (factory set) or ma (software configurable) Parameter set selection: V The actual values for flow and pressure are reported back to the PLC by means of two V (and ma) signal outputs of the RKP-D. The Moog Configuration Software can be used as a set-up tool, in order to modify the factory settings or to analyze the operational behavior of the RKP-D. Analog Actuation PLC Q-Set point analog X1 X3 CANopen p-set point analog Parameter set selection V (optional) X1 X7 Moog Valve Configuration Software (optional) RKP-D CAN-bus Actuation PLC CANopen X3 RKP-D RADIAL PISTON PMP RKP-D 11

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